Abradable seal and method of producing a seal

ABSTRACT

An air seal for use in a gas turbine engine. The seal includes a thermally sprayed abradable seal layer. The abradable material is composed of aluminum powder forming a metal matrix, and co-deposited methyl methacrylate particles and/or hexagonal boron nitride particles embedded as filler in the metal matrix.

TECHNICAL FIELD OF THE DISCLOSURE

The present disclosure is generally related to seals and, morespecifically, to an abradable seal and a method of producing a seal.

BACKGROUND OF THE DISCLOSURE

Gas turbine engines are well known sources of power, e.g., motive powerfor aircraft or as power generators, and generally include compressor(typically preceded by one or more fan stages), combustor and turbinesections. FIG. 1 schematically illustrates a gas turbine engine 20. Thegas turbine engine 20 is disclosed herein as a two-spool turbofan thatgenerally incorporates a fan section 22, a compressor section 24, acombustor section 26 and a turbine section 28. Alternative engines mightinclude an augmentor section (not shown) among other systems orfeatures. The fan section 22 drives air along a bypass flow path B in abypass duct, while the compressor section 24 drives air along a coreflow path C for compression and communication into the combustor section26 then expansion through the turbine section 28. Although depicted as atwo-spool turbofan gas turbine engine in the disclosed non-limitingembodiment, it should be understood that the concepts described hereinare not limited to use with two-spool turbofans as the teachings may beapplied to other types of turbine engines including three-spoolarchitectures.

The exemplary engine 20 generally includes a low speed spool 30 and ahigh speed spool 32 mounted for rotation about an engine centrallongitudinal axis A relative to an engine static structure 36 viaseveral bearing systems 38. It should be understood that various bearingsystems 38 at various locations may alternatively or additionally beprovided, and the location of bearing systems 38 may be varied asappropriate to the application.

The low speed spool 30 generally includes an inner shaft 40 thatinterconnects a fan 42, a low pressure compressor 44 and a low pressureturbine 46. The inner shaft 40 is connected to the fan 42 through aspeed change mechanism, which in exemplary gas turbine engine 20 isillustrated as a geared architecture 48 to drive the fan 42 at a lowerspeed than the low speed spool 30. The high speed spool 32 includes anouter shaft 50 that interconnects a high pressure compressor 52 and highpressure turbine 54. A combustor 56 is arranged in exemplary gas turbine20 between the high pressure compressor 52 and the high pressure turbine54. An engine static structure 36 is arranged generally between the highpressure turbine 54 and the low pressure turbine 46. The engine staticstructure 36 further supports bearing systems 38 in the turbine section28. The inner shaft 40 and the outer shaft 50 are concentric and rotatevia bearing systems 38 about the engine central longitudinal axis Awhich is collinear with their longitudinal axes.

The core airflow is compressed by the low pressure compressor 44 thenthe high pressure compressor 52, mixed and burned with fuel in thecombustor 56, then expanded over the high pressure turbine 54 and lowpressure turbine 46. The turbines 46, 54 rotationally drive therespective low speed spool 30 and high speed spool 32 in response to theexpansion. It will be appreciated that each of the positions of the fansection 22, compressor section 24, combustor section 26, turbine section28, and fan drive gear system 48 may be varied. For example, gear system48 may be located aft of combustor section 26 or even aft of turbinesection 28, and fan section 22 may be positioned forward or aft of thelocation of gear system 48.

The engine 20 in one example is a high-bypass geared aircraft engine. Ina further example, the engine 20 bypass ratio is greater than about six(6), with an example embodiment being greater than about ten (10), thegeared architecture 48 is an epicyclic gear train, such as a planetarygear system or other gear system, with a gear reduction ratio of greaterthan about 2.3 and the low pressure turbine 46 has a pressure ratio thatis greater than about five. In one disclosed embodiment, the engine 20bypass ratio is greater than about ten (10:1), the fan diameter issignificantly larger than that of the low pressure compressor 44, andthe low pressure turbine 46 has a pressure ratio that is greater thanabout five 5:1. Low pressure turbine 46 pressure ratio is pressuremeasured prior to inlet of low pressure turbine 46 as related to thepressure at the outlet of the low pressure turbine 46 prior to anexhaust nozzle. The geared architecture 48 may be an epicycle geartrain, such as a planetary gear system or other gear system, with a gearreduction ratio of greater than about 2.3:1. It should be understood,however, that the above parameters are only exemplary of one embodimentof a geared architecture engine and that the present invention isapplicable to other gas turbine engines including direct driveturbofans.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 22 of the engine 20 is designedfor a particular flight condition—typically cruise at about 0.8 Mach andabout 35,000 feet (10,688 meters). The flight condition of 0.8 Mach and35,000 ft (10,688 meters), with the engine at its best fuelconsumption—also known as “bucket cruise Thrust Specific FuelConsumption (‘TSFC’)”—is the industry standard parameter of lbm of fuelbeing burned divided by lbf of thrust the engine produces at thatminimum point. “Low fan pressure ratio” is the pressure ratio across thefan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The lowfan pressure ratio as disclosed herein according to one non-limitingembodiment is less than about 1.45. “Low corrected fan tip speed” is theactual fan tip speed in ft/sec divided by an industry standardtemperature correction of [(Tram ° R)/(518.7° R)]^(0.5). The “Lowcorrected fan tip speed” as disclosed herein according to onenon-limiting embodiment is less than about 1150 ft/second (350.5 m/sec).

As illustrated generally in FIG. 2, compressor section 24 and turbinesection 28 (and any fan stages 22) each include shaft-mounted, rotatingdisks 1, each carrying a set of blades 2 located within static structure36, with intervening sets of stationary vanes 5 mounted to the staticstructure 36. Air seals 4, 7 are provided between the tips of the blades2 and the static structure 36 (outer air seals), and between the freeends 6 of the vanes 5 and the knife edges 8 of the disks 1 (knife edgeseals) to prevent air leakage between those components.

Air is ingested through the core flow path C and compressed by rotatingdisks 1 and associated blades 2 in the compressor section 24. Thecompressed air is then burned with fuel in the combustor section 26 togenerate high pressure and temperature gasses, which cause rotation ofthe turbine section 28 and associated fan section 22 and compressorsection 24 and are then ejected out an engine exhaust to provide thrust.The static structure 36 is intended to prevent leakage of air orcombustion products around the tips of the blades 2, i.e., between theblade 2 tips and the static structure 36, which leakage reduces theefficiency of the engine 20.

Despite the design of components to minimize leakage, a substantialproportion of any leakage which does occur in a normally-operating gasturbine engine occurs between the tips of the blades 2 and the staticstructure 36, and between the tips of the vanes 5 and the disks 1. Onemanner of eliminating such leakage is to fabricate all mating parts toextremely close tolerances, which becomes increasingly expensive astolerances are reduced. Moreover, given the temperature ranges to whichthe parts are subjected to before, during and after operation, and theresultant thermal expansion and contraction of the parts, such closetolerances will at times result in interference between mating parts andcorresponding component wear and other damage. Accordingly, gas turbineengine designers have devoted significant effort to developing effectiveair seals, and particularly seals composed of abradable materials. Suchseals require a balance of several properties including abradabilityupon being contacted by a rotating blade 2 tip, erosion resistance,durability, thermal expansion balanced with that of the underlyingmaterial, and relative ease and reasonable cost of manufacture.

A typical compressor air seal includes a seal substrate, e.g., a metalsubstrate, a metal bond layer composed of a metal powder plasma sprayedonto the substrate, and an abradable, sealing layer which is alsotypically plasma sprayed onto the metal bond layer. A typical sealinglayer includes a metal matrix of aluminum and silicon with some amountof embedded methyl methacrylate powder particles. Because a galvaniccell is formed between the aluminum and silicon, the abradable sealinglayer is subject to environmental aqueous corrosion, thereby possiblycompromising the performance of the sealing layer.

Improvements in seal design are therefore needed in the art.

SUMMARY OF THE DISCLOSURE

In one embodiment, an air seal is disclosed, comprising: an abradableseal layer consisting essentially of thermally sprayed aluminum powderforming a metal matrix, and co-deposited methyl methacrylate fillerparticles embedded in the metal matrix.

In a further embodiment of the above, the air seal further comprises aseal substrate; and a thermally sprayed metal bond layer applied to atleast a portion of the seal substrate, the metal bond layer composed ofthermally sprayed powder; wherein the abradable seal layer is applied tothe metal bond layer.

In a further embodiment of any of the above, the air seal is an outerair seal of a gas turbine engine.

In a further embodiment of any of the above, the air seal is a knifeedge seal of a gas turbine engine.

In a further embodiment of any of the above, the thermal spray comprisesa plasma spray.

In a further embodiment of any of the above, the aluminum powderparticles are composed of at least about 99 weight percent aluminumpowder.

In a further embodiment of any of the above, the abradable layer iscomposed of between about 30 to about 60 volume percent aluminum.

In a further embodiment of any of the above, the abradable layer iscomposed of between about 40 to about 50 volume percent aluminum.

In another embodiment, an air seal is disclosed, comprising: anabradable seal layer comprising a metal matrix, and co-depositedhexagonal boron nitride filler particles and methyl methacrylate fillerparticles embedded in the metal matrix, wherein the metal matrixconsists essentially of thermally sprayed aluminum powder.

In a further embodiment of any of the above, the air seal furthercomprises: a seal substrate; and a thermally sprayed metal bond layerapplied to at least a portion of the seal substrate, the metal bondlayer composed of thermally sprayed powder; wherein the abradable seallayer is applied to the metal bond layer.

In a further embodiment of any of the above, the air seal is an outerair seal of a gas turbine engine.

In a further embodiment of any of the above, the air seal is a knifeedge seal of a gas turbine engine.

In a further embodiment of any of the above, the thermal spray comprisesa plasma spray.

In a further embodiment of any of the above, the aluminum powderparticles are composed of at least about 99 weight percent aluminumpowder.

In a further embodiment of any of the above, the abradable layer iscomposed of between about 30 to about 60 volume percent aluminum.

In a further embodiment of any of the above, the abradable layer iscomposed of between about 33 to about 40 volume percent aluminum.

In a further embodiment of any of the above, the abradable layer iscomposed of up to about 15 volume percent hexagonal boron nitride.

In a further embodiment of any of the above, the abradable layer iscomposed of between about 0.3 to about 4 volume percent hexagonal boronnitride.

In a further embodiment of any of the above, the hexagonal boron nitridecomprises an agglomerate containing up to about 15 volume percentbentonite clay.

In a further embodiment of any of the above, the hexagonal boron nitridecomprises an agglomerate containing about 10 volume percent bentoniteclay.

Other embodiments are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments and other features, advantages and disclosures containedherein, and the manner of attaining them, will become apparent and thepresent disclosure will be better understood by reference to thefollowing description of various exemplary embodiments of the presentdisclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a schematic cross-sectional view of a gas turbine engine.

FIG. 2 is a schematic cross-sectional view of rotating blades andstationary vanes in an embodiment.

FIG. 3 is a schematic view of a seal and a plasma torch for producingthe seal in an embodiment.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to certain embodiments andspecific language will be used to describe the same. It willnevertheless be understood that no limitation of the scope of theinvention is thereby intended, and alterations and modifications in theillustrated device, and further applications of the principles of theinvention as illustrated therein are herein contemplated as wouldnormally occur to one skilled in the art to which the invention relates.

Turning now to FIG. 3, a plasma spray apparatus in an embodimentincludes a torch 120 (including a power source and spray head, neithershown separately from the apparatus generally), and at least threepowder delivery lines 122, 123, 124. The torch is capable ofsimultaneously delivering and spraying at least two separate powdersinto a flame 121, see, e.g., commonly-owned U.S. Pat. No. 4,696,855 toPettit, Jr. et al, which is expressly incorporated by reference herein.The lines 122, 123, 124 are coupled respectively to powder materialhoppers 126, 127, 128 which contain the powder to be deposited onto asubstrate 130, and respective sources 132, 133, 134 of carrier gas suchas argon, which deliver the powder from the hoppers into the plasmatorch plume 121. Typical substrate 130 materials include titaniumalloys, as well as nickel base, cobalt base and iron base superalloysand combination of these materials, although the present disclosure isnot intended to be limited to such materials. Plasma spray apparatusgenerally are known in the art, and accordingly have not been describedin detail herein. We have used a model 3 MB manufactured by OerlikonMetco in Westbury, N.Y. to produce seals in accordance with the presentdisclosure. While the present disclosure is described in connection withan outer air seal, it may be equally applied to a knife edge seal system(e.g., FIG. 2 at 7, 8), or other suitable application.

In an embodiment, the powder for providing a metal bond layer 136 on thesubstrate 130 is a blend of aluminum and nickel powder. The powder issold under different names, such as 450-NS or AMDRY 956 from OerlikonMetco. The powder is typically a composited powder (particles of onebeing bound to the other) composed, in weight percent of between about3.5-6 (and between 4-5.5 in some embodiments) aluminum, up to about 3(and less than 2.5 in some embodiments) organic binder, balance nickel.The powder may also include other materials, such as up to about 19 wt.% chromium in place of some of the nickel. An alternate metal powder hasa nominal composition, by weight, of about 69.5 nickel, 18.5 chromiumand about 6 aluminum. In an embodiment, the powder particle size is−325+140 mesh (between approximately 45 and approximately 105micrometers in diameter).

The powder which forms the metal bond layer 136 is stored in a hopper126, and a carrier gas such as argon or nitrogen is provided from asource 132, to carry the powder through a line 122, to introduce thepowder to the torch 120 as a single source. In an embodiment, acombination of argon and hydrogen is used as the arc gas for the torch.The powder is deposited on the substrate 130 to form the metal bondlayer 136 of a thickness of between about 0.002-0.012 inch, and in someembodiments, between about 0.003-0.006 inch. In some embodiments, themetal bond layer 136 is formed from the metal used in the abradablelayer 138, less the non-metal additives. In other embodiments, the metalbond layer 136 is not used.

In an embodiment, the powder for providing an abradable layer 138 is acombination of aluminum powder, and methyl methacrylate powder. Thealuminum powder is sold under different names, such as 54NS by OerlikonMetco. The powder is 99.0+ weight percent aluminum. In an embodiment,the powder particle size is −170+325 mesh (between approximately −90 andapproximately +45 micrometers in diameter).

In an embodiment, the methyl methacrylate powder is sold by ICI Acrylicsof Wilmington, Del. grade 4F or 6751. Preferably, the powder particlessubstantially all (at least about 90% by weight) are smaller than 125micrometers and most (at least about 65% by weight) are smaller than 63micrometers.

In an embodiment, the powder which forms an abradable layer 138 isco-deposited, e.g., introduced separately into the plasma. Co-depositingenables the relative amounts of aluminum powder and methyl methacrylatepowder to be adjusted as desired. In an embodiment, a combination ofargon and hydrogen is used as the arc gas.

The aluminum powder is stored in a hopper 127, and a carrier gas such asargon or nitrogen is provided from a source such as the source 133, tocarry the powder through a line such as line 123, to introduce thepowder to the torch 120. The methyl methacrylate powder is stored in ahopper 128, and a carrier gas such as argon or nitrogen is provided froma source such as the source 134, to carry the powder through a line suchas line 124, to introduce the powder into the spray stream produced bythe torch 120 downstream of the aluminum powder. The aluminum and methylmethacrylate are deposited on the substrate 130 to form the abradablelayer 138 to a desired thickness plus some excess thickness (at least0.025 inch in one embodiment) to allow for subsequent machining of theseal. Other types of processes may be used to apply the metal bond layer136 and the abradable layer 138, such as high velocity oxygen fuelspraying (HVOF), to name just one non-limiting example.

An alternate next step is to remove the methyl methacrylate from theabradable layer 138 in applications where it is desired to reduce theamount of dust produced during a rub of the seal. The next step isaccordingly a heat treatment, in which the seal is heated to atemperature of about 600° F. for at least about 4 hours. The porosity ofthe resulting seal is a function of the filler content.

In an embodiment, the abradable layer is fed to the torch 120 at a massflow rate of about 60 g/minute, and the methyl methacrylate is fed at amass flow rate of about 17 g/minute. The amount of methyl methacrylatein the abradable layer 138 may be varied to achieve the density desiredin the finished layer 138. The layer 138 may comprise about 30-60 vol %(and in some embodiments about 40-50 vol %)aluminum with the balancebeing methyl methacrylate. Where no heat treatment is performed, theseal in some embodiments has a hardness of about HR15Y 20-85 (and insome embodiments about HR15Y 40-70). Heat treating the seal reduces thehardness. For example, heat treating a seal with an initial hardness ofabout HR15Y 80 will result in a hardness of about HR15Y 55 after heattreating.

An advantage of some of the presently disclosed embodiments is that theseal provides both acceptable durability and abradability, and also willnot deflagrate during off-design operation during which significantamounts of seal material is ingested into the engine. Some of thepresently disclosed embodiments are resistant to environmental aqueouscorrosion, exhibit greater ductility and lower modulus than abradablelayers made with aluminum-silicon materials for increased fatigueresistance. The increased ductility may cause more material transfer tothe blades 2, which can be counteracted as necessary by adding hexagonalboron nitride to the abradable layer 138.

In one embodiment, an abradable composition containing aluminum matrix,methylmethacrylate and hexagonal boron nitride may comprise about 30-60vol % aluminum (and in some embodiments about 33-40 vol %), up to about15 vol % hexagonal boron nitride (and in some embodiments about 0.3-4vol %) with the remainder being methyl methacrylate. In someembodiments, the aluminum and hexagonal boron nitride comprise acomposited powder. In some embodiments, the hexagonal boron nitridecomprises an agglomerate containing up to about 15 vol % bentonite clay(and in some embodiments about 10 vol %), where the bentonite clay isconsidered part of the hexagonal boron nitride fraction in the vol % slisted above.

The seal of the presently disclosed embodiments is additionally costeffective, and does not weigh any more than conventional seal materials.The seal can be applied using conventional plasma spray apparatus, andthe process of providing such a seal enables adjustment of theproportion of metal and of filler, to provide an optimal seal adaptedfor different operating conditions. By co-spraying the metal and thefiller, we produce a seal having uniformly finer distributedconstituents in its microstructure.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly certain embodiments have been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected.

1.-20. (canceled)
 21. An air seal comprising a porous abradable seallayer formed by thermally spraying aluminum powder forming a metalmatrix, co-depositing methyl methacrylate filler particles in the metalmatrix, and removing the methyl methacrylate filler particles.
 22. Theair seal of claim 21, further comprising: a seal substrate; and athermally sprayed metal bond layer applied to at least a portion of theseal substrate, the metal bond layer composed of thermally sprayedpowder; wherein the abradable seal layer is applied to the metal bondlayer.
 23. The air seal of claim 21, wherein the air seal is an outerair seal of a gas turbine engine.
 24. The air seal of claim 21, whereinthe air seal is a knife edge seal of a gas turbine engine.
 25. The airseal of claim 21, wherein the thermal spray comprises a plasma spray.26. The air seal of claim 21, wherein the aluminum powder particlescomprises at least about 99 weight percent aluminum powder.
 27. The airseal of claim 21, wherein the abradable layer comprises about 30 toabout 60 volume percent aluminum.
 28. The air seal of claim 27, whereinthe abradable layer comprises about 40 to about 50 volume percentaluminum.
 29. An air seal comprising a porous abradable seal layerformed by thermally spraying aluminum powder forming a metal matrix,co-depositing hexagonal boron nitride filler particles and methylmethacrylate filler particles in the metal matrix, and removing themethyl methacrylate filler particles.
 30. The air seal of claim 29,further comprising: a seal substrate; and a thermally sprayed metal bondlayer applied to at least a portion of the seal substrate, the metalbond layer comprising a thermally sprayed powder; wherein the abradableseal layer is applied to the metal bond layer.
 31. The air seal of claim29, wherein the air seal is an outer air seal of a gas turbine engine.32. The air seal of claim 29, wherein the air seal is a knife edge sealof a gas turbine engine.
 33. The air seal of claim 29, wherein thethermal spray comprises a plasma spray.
 34. The air seal of claim 29,wherein the aluminum powder particles comprise at least about 99 weightpercent aluminum powder.
 35. The air seal of claim 29, wherein theabradable layer comprises about 30 to about 60 volume percent aluminum.36. The air seal of claim 35, wherein the abradable layer comprisesabout 33 to about 40 volume percent aluminum.
 37. The air seal of claim35, wherein the abradable layer comprises up to about 15 volume percenthexagonal boron nitride.
 38. The air seal of claim 37, wherein theabradable layer comprises about 0.3 to about 4 volume percent hexagonalboron nitride.
 39. The seal of claim 37, wherein the hexagonal boronnitride comprises an agglomerate comprising up to about 15 volumepercent bentonite clay.
 40. The seal of claim 39, wherein the hexagonalboron nitride comprises an agglomerate comprising about 10 volumepercent bentonite clay.